Part 2
DIFFERENTIAL: DIFFERENTIAL CARRIER ASSEMBLY: REASSEMBLY
13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Install a dial indicator to the differential carrier.
(b) Tighten SST bolt to alter the differential carrier's shape by approximately 0.1 mm (0.004 in.).
SST : 09571-50010
NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).
HINT
Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.
(c) Using snap ring pliers, install a side gear shaft snap ring on the ring gear tooth side.
If the backlash is not within the specified range, adjust it to the specified range by increasing or decreasing the thickness of the right and left side differential side gear shaft snap rings equally.
(d) Remove the dial indicator and loosen the thinnest side gear shaft snap ring on the ring gear tooth side.
HINT
Do not remove SST.
(e) Using a plastic-faced hammer, lightly tap the ring tooth side of the differential carrier to stabilize the differential case bearing.
(f) Place a dial indicator on the tip of the ring gear tooth at a right angle.
(g) Fix the companion flange in place by hand, and measure the ring gear backlash.
Standard backlash:
0.08 to 0.13 mm (0.0031 to 0.0051 in.)
NOTICE:
Measure at 3 or more areas around the circumference of the ring gear.
If the backlash is small even in one place, replace the ring gear tooth side differential side gear shaft snap ring with a thicker one.
HINT
* Record the measured value, as it is used to select the differential side gear shaft snap ring.
* Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.
* When adjusting the backlash, adjust to within 0.1 mm of the average of the measurements.
(h) Remove the 2 bolts and SST from the differential carrier.
14. ADJUST TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the preload with the teeth of the drive pinion and ring gear in contact.
SST : 09229-55010
Standard total preload (at starting):
New bearing
1.58 to 3.07 N*m (16.1 to 31.3 kgf*cm, 14.0 to 27.2 in.*lbf)
Reused bearing
0.86 to 2.07 N*m (8.8 to 21.1 kgf*cm, 7.6 to 18.3 in.*lbf)
If the measured preload is below the standard value, replace the differential side gear shaft snap ring with a thicker one.
If the measured preload is above the standard value, replace the differential side gear shaft snap ring with a thinner one.
NOTICE:
* If the thickness of the differential side gear shaft snap ring changes 0.02 mm, the total preload will change approximately 0.1 N*m (1.0 kgf*cm).
* For reassembly purposes, record the measured value.
(b) Place a dial indicator on the tip of the ring gear tooth at a right angle.
(c) While holding the companion flange, rotate the ring gear and measure the backlash.
Standard backlash:
0.08 to 0.13 mm (0.0031 to 0.0051 in.)
NOTICE:
Measure at 3 or more areas around the circumference of the ring gear.
If the backlash is not within the specified range, adjust it to the specified range by increasing or decreasing the thickness of the right and left side differential side gear shaft snap rings equally.
HINT
* When adjusting the backlash, adjust to within 0.1 mm of the average of the measurements.
* When the side gear shaft snap ring thickness changes by 0.02 mm (0.0008 in.), the backlash will also change by approximately 0.02 mm (0.0008).
* Record the measured value, as it is used to select the differential side gear shaft snap ring.
* Perform the tooth contact pattern inspection for the differential ring gear and drive pinion. The results will be used as a reference for selecting the differential side gear shaft snap ring.
(d) Recheck the total preload.
15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
(a) Uniformly apply a light coat of Prussian blue on both sides of 4 teeth on the differential ring gear.
(b) Rotate the companion flange several times in the forward and backward rotation directions.
(c) Inspect the tooth contact pattern.
NOTICE:
Check the tooth contact pattern at 4 or more positions around the circumference of the ring gear.
HINT
The patterns indicated by the Prussian blue are the tooth contact locations.
(d) If the teeth are not contacting properly, use the following table to select a proper drive pinion washer for correction.
NOTICE:
Make sure to always replace the drive pinion washer with a new one.
Standard washer thickness:
16. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING
(a) Install the 2 bolts and SST to the differential carrier.
SST : 09571-50010
(b) Tighten SST bolt until SST disc lightly touches the case bearing outer race.
(c) Install a dial indicator to the rear differential carrier.
(d) Tighten SST bolt and alter the differential carrier's shape to create a 0.1 mm (0.004 in.) clearance between the case bearing outer race and side gear shaft snap ring.
NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).
HINT
* Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.
* The approximate 0.1 mm clearance between the differential case bearing outer race and the differential side gear shaft snap ring only needs to be enough so that the differential side gear shaft snap ring can move slightly.
(e) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear tooth side.
HINT
Place distinguishing marks on the left and right side differential side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.
(f) Remove the dial indicator and loosen the thinnest side gear shaft snap ring on the ring gear tooth side.
HINT
Do not remove SST.
17. REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING
(a) Using SST and a hammer, create a clearance between the case bearing outer race on the ring gear and side gear shaft snap ring.
SST : 09608-32010
SST : 09950-70010
09951-07200
HINT
The clearance is not visible, but tapping SST with a hammer 3 or 4 times should be enough.
(b) Using snap ring pliers, remove the side gear shaft snap ring on the ring gear back surfaces side.
HINT
Place distinguishing marks on the left and right side differential side gear shaft snap rings to distinguish them (back surface side, tooth side). Then store them separately.
18. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Tighten SST bolt and push out the case bearing outer race on the ring gear back surface side.
SST : 09571-50010
NOTICE:
Do not drop the case bearing outer race.
HINT
* For reassembly purposes, mark the installation positions of the differential case bearing outer race and differential side gear shaft snap ring.
* Place distinguishing marks on the left and right side differential case bearing outer races to distinguish them (back surface side, tooth side). Then store them separately.
(b) Remove the 2 bolts and SST from the differential carrier.
19. REMOVE REAR DIFFERENTIAL CASE BEARING
(a) Raise the ring gear side of the differential case slightly and remove the ring gear tooth side case bearing outer race.
NOTICE:
Do not drop the case bearing outer race.
HINT
* For reassembly purposes, mark the installation positions of the differential case bearing outer race and differential side gear shaft snap ring.
* Place distinguishing marks on the left and right side differential case bearing outer races to distinguish them (back surface side, tooth side). Then store them separately.
20. REMOVE REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Remove the rear differential case.
NOTICE:
Do not damage the case bearing.
21. REMOVE REAR DRIVE PINION NUT
(a) Using SST, fix the companion flange in place.
SST : 09330-00021
SST : 09950-30012
09955-03040
(b) Using SST, remove the drive pinion nut from the differential carrier.
SST : 09229-55010
HINT
Perform the removal while supporting the overhaul attachment.
22. REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
(a) Using SST, remove the companion flange.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
NOTICE:
Before using SST center bolt (09953-03010), apply hypoid gear oil to its threads and tip.
23. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Remove the differential drive pinion oil slinger from the differential drive pinion.
24. REMOVE DIFFERENTIAL DRIVE PINION
(a) Using a press, press out the drive pinion from the differential carrier.
NOTICE:
Do not drop the drive pinion.
25. REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Remove the rear drive pinion front tapered roller bearing from the differential carrier.
26. INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER
(a) Install a new drive pinion bearing spacer to the drive pinion.
HINT
The bearing spacer can be installed facing either direction.
27. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the rear drive pinion front tapered roller bearing inner race from the differential carrier.
28. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using SST and a press, press in the differential drive pinion to the differential carrier.
SST : 09316-60011
09316-00011
09316-00041
SST : 09608-04031
29. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER
(a) Install the differential drive pinion oil slinger to the differential drive pinion.
30. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal.
SST : 09316-60011
09316-00011
SST : 09710-04101
NOTICE:
* Tap the oil seal uniformly so that the oil seal is straight.
* Do not excessively tap the oil seal.
(b) Using a vernier caliper, measure the depth of the oil seal.
Standard depth:
0 to 0.5 mm (0 to 0.020 in.)
NOTICE:
* Measure at 3 or more areas around the circumference of the oil seal.
* Make sure difference between the maximum and minimum measured values is less than 0.65 mm, as a greater difference may lead to oil leaks.
(c) Apply MP grease to the lip of the oil seal.
31. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY REAR
(a) Using SST, install the companion flange to the drive pinion.
SST : 09950-30012
09951-03010
09953-03010
09954-03010
09955-03040
09956-03060
NOTICE:
* Perform this procedure after aligning the companion flange with the spline of the drive pinion.
* Apply grease to the threads and tip of SST center bolt before use.
(b) Coat the threads of a new drive pinion nut with hypoid gear oil LSD.
(c) Use SST to hold the flange and torque the drive pinion nut.
SST : 09950-30012
09955-03040
(d) Using SST and a torque wrench, tighten the drive pinion nut while checking the starting torque of the drive pinion.
SST : 09229-55010
SST : 09330-00021
Maximum torque:
T=490 N*m {5000 kgf*cm 361 ft.*lbf}
NOTICE:
* Tighten the nut with a force of 100 N*m (1020 kgf*cm) while checking the starting torque of the drive pinion.
* Do not overtighten the nut, as the threads will become damaged.
* Apply hypoid gear oil LSD to the threads of the nut and drive pinion.
HINT
Perform the removal while supporting the overhaul attachment.
32. INSTALL REAR DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Insert the differential case from the ring gear tooth side.
NOTICE:
Do not damage the case bearing inner race or ring gear.
33. INSTALL REAR DIFFERENTIAL CASE BEARING
(a) Using SST and a hammer, tap in the ring gear tooth side case bearing outer race.
SST : 09608-32010
SST : 09950-70010
09951-07200
HINT
Tap in the case bearing outer race until half of the side gear shaft snap ring groove of the differential carrier can be seen.
(b) Install the 2 bolts and SST to the differential carrier.
SST : 09571-50010
(c) Tighten SST bolt until SST disc lightly touches the case bearing outer race.
(d) Using SST and a hammer, tap in the ring gear back surface side case bearing outer race.
SST : 09608-32010
SST : 09950-70010
09951-07200
HINT
Tap in the case bearing outer race until it touches the case bearing inner race roller bearing.
34. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SHAFT SNAP RING
(a) Using snap ring pliers, install the side gear shaft snap ring in the differential carrier on the ring gear back surface side.
NOTICE:
Check that the differential side gear shaft snap ring is securely fitted into the groove.
HINT
Use the side gear shaft snap ring that was used during the tooth contact adjustment.
(b) Install a dial indicator on the differential carrier.
(c) Tighten SST bolt, and push in the differential case.
NOTICE:
Observe the dial indicator to ensure that the shape of the differential carrier does not change more than 0.2 mm (0.008 in.).
HINT
* Try to set the dial indicator as close as possible to the differential carrier cover side (upper side in illustration) of the differential case bearing outer race.
* The approximate 0.1 mm clearance between the differential case bearing outer race and the differential side gear shaft snap ring only needs to be enough so that the differential side gear shaft snap ring can move slightly.
(d) Remove the dial indicator and using snap ring pliers, install the side gear shaft snap ring on the ring gear tooth side.
HINT
Use the side gear shaft snap ring that was used during the tooth contact adjustment.
(e) Loosen the thinnest side gear shaft snap ring on the ring gear tooth side.
(f) Tap the differential carrier on the ring gear tooth side using a plastic-faced hammer to stabilize the case bearing.
(g) Remove the 2 bolts and SST from the differential carrier.
35. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Using SST and a torque wrench, measure the preload.
SST : 09229-55010
Standard total preload (at starting):
New bearing
1.22 to 1.80 N*m (12.4 to 18.4 kgf*cm, 10.8 to 15.9 in.*lbf)
Reused bearing
0.5 to 0.8 N*m (5.1 to 8.2 kgf*cm, 4.4 to 7.1 in.*lbf)
NOTICE:
* For a more accurate measurement, rotate the flange forward and backward several times before the measurement.
* Check the starting torque of the drive pinion for use with the total preload inspection.
* The bearing spacer is made of plastic and changes shape when used. If the starting torque of the drive pinion is exceeded by mistake, make sure to replace the bearing spacer with a new one.
If the starting torque of the drive pinion is exceeded, replace the bearing spacer.
If the starting torque of the drive pinion is insufficient, tighten the drive pinion nut 5 to 10° at a time.
Repeat the adjustment as necessary until the starting torque matches the specified torque.
Maximum torque:
T=490 N*m {5000 kgf*cm 361 ft.*lbf}
NOTICE:
* If the tightening torque of the pinion nut exceeds the specified torque but the drive pinion starting torque is still insufficient, loosen the pinion nut. Then check if the pinion nut and drive pinion threads are damaged.
* If there are no problems, replace the bearing spacer, apply hypoid gear oil LSD to its threads and repeat the procedure above.
36. INSPECT TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the total preload.
SST : 09229-55010
Standard total preload (at starting):
New bearing
1.68 to 3.17 N*m (17.1 to 32.3 kgf*cm, 14.9 to 28.1 in.*lbf)
Reused bearing
0.96 to 2.17 N*m (9.8 to 22.1 kgf*cm, 8.5 to 19.2 in.*lbf)
37. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Place a dial indicator so that it is perpendicular to the top of the ring gear on the tooth side.
(b) Fix the companion flange in place, and measure the ring gear backlash.
Standard backlash:
0.08 to 0.13 mm (0.0031 to 0.0051 in.)
NOTICE:
Measure at 3 or more areas around the circumference of the ring gear.
38. INSPECT RUNOUT OF DIFFERENTIAL DRIVE PINION
(a) Using a dial indicator, measure the runout of the drive pinion shaft at a position 10 mm (0.39 in.) from the end of the shaft.
Maximum runout:
0.08 mm (0.0031 in.)
39. INSTALL REAR DRIVE PINION NUT
(a) Using a chisel and a hammer, stake the drive pinion nut.
SST : 09930-00010
40. INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, install 2 new oil seals.
SST : 09223-15030
SST : 09950-70010
09951-07150
Standard depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)
NOTICE:
* Tap the oil seal uniformly so that the oil seal is straight.
* After the installation, check that the oil seal has been tapped securely onto the differential.
(b) Apply MP grease to the lips of the oil seal.
41. INSTALL REAR DIFFERENTIAL DRAIN PLUG
HINT
Perform this procedure as necessary.
(a) Using a 10 mm socket hexagon wrench, install a new gasket and drain plug to the rear differential carrier.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
42. INSTALL REAR DIFFERENTIAL FILLER PLUG
HINT
Perform this procedure as necessary.
(a) Using a 10 mm socket hexagon wrench, install a new gasket and filler plug to the rear differential carrier.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
43. REMOVE REAR DIFFERENTIAL CARRIER ASSEMBLY
(a) Remove the differential carrier from the overhaul attachment.
44. INSTALL REAR DIFFERENTIAL BREATHER PLUG OIL DEFLECTOR
(a) Clean the seal packing attached on the differential carrier and carrier cover using a scraper and wire brush. Then remove the oil with a non-residue solvent or equivalent.
NOTICE:
Do not scratch the fitting surface.
(b) Install the rear differential breather plug oil deflector to the rear differential carrier cover with the bolt.
Torque : 7.0 Nm (72 kgf-cm, 62 in-lbf)
45. INSTALL REAR DIFFERENTIAL CARRIER COVER
(a) Apply seal packing to the differential carrier as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing 1281, Three bond 1281 or equivalent
NOTICE:
* Apply the seal packing in a continuous line, approximately 2 to 3 mm (0.08 to 0.12 in.) in diameter.
* Overlap the seal packing at least 10 mm at the beginning and the end of application.
* Install the differential carrier cover within 3 minutes of application.
(b) Install the differential carrier cover with the 8 bolts.
Torque : 47 Nm (475 kgf-cm, 35 ft-lbf)
NOTICE:
Do not fill the oil or drive immediately after installing the differential carrier cover. Leave the vehicle for at least 1 hour. Also, avoid sudden acceleration and deceleration for at least 12 hours after application.
46. INSTALL REAR DIFFERENTIAL CARRIER COVER BREATHER PLUG
(a) Install the breather plug to the carrier cover.
Torque : 21 Nm (210 kgf-cm, 15 ft-lbf)